Cable reel assembly

ABSTRACT

A cable reel assembly includes a fluted drum; a pair of circular flanges removeably attached to opposite ends of the drum; and a number of elongated rods that connect the flanges to the drum. The drum and flanges are preferably rotationally molded of synthetic resin materials and are partially hollow so as to minimize their weight.

BACKGROUND

Electrical cables, wires, conduits, tubes, and other elongated objects are often wound on cable reels for facilitating their storage, transport, and installation. Conventional cable reels are typically made of wood and often crack, warp, or otherwise become damaged, especially after prolonged exposure to rain, snow, and sunlight. Such cable reels are therefore typically used only once and then discarded, necessitating expensive and time consuming disposal efforts and taking up valuable landfill space. Wooden cable reels are also very heavy and occupy lots of space before they are used because they are typically made from several thick and heavy pieces that are nailed, screwed, or otherwise semi-permanently attached into a final form that is not easily stacked and stored.

Because of variances in cable thickness, length, and flexibility, many cables require a specific sized cable reel. Cable manufacturers, electrical contractors, and cable installers therefore must stock and use several different sized wooden cable reels to accommodate different cables.

Accordingly, there is a need for an improved cable reel that overcomes the limitations of the prior art.

SUMMARY

The present invention solves the above-described problems and provides a distinct advance in the art of cable reels. More particularly, the present invention provides a cable reel assembly that is reusable and recyclable; relatively lightweight but still very strong; easy to store and transport; and capable of being quickly and easily assembled in various different configurations to accommodate many different types and sizes of cable.

An embodiment of the cable reel assembly broadly includes a fluted drum; a pair of circular flanges removeably attached to opposite ends of the drum; and a number of elongated tie rods that connect the flanges to the drum. The drum and flanges are preferably rotationally molded of synthetic resin materials and are reusable and recyclable and partially hollow so as to minimize their weight.

An embodiment of the fluted drum includes a hollow central core and a number of circumferentially-spaced ribs extending radially outwardly from the core. The ribs are separated by a number of grooves with openings along the circumference of the drum for receiving the tie rods as described below. Each groove is generally V-shaped and has a rounded or curved vertex. The ends of the drum may each include a circular recess that forms part of an interlocking structure as described below.

The flanges are preferably circular in shape and each includes an inner face, an outer face and an outer radial wall connecting the faces. Each flange includes a number of spaced connection holes aligned with the vertices of at least some of the grooves in the drum for receiving the tie rods. Each flange may also include a number of spaced key-hole shaped slots that are formed by walls connecting the inner and outer faces of the flange that increase the rigidity and strength to the flanges.

The inner face of each flange may include a circular raised hub and number of circumferentially-spaced raised spokes that extend outwardly from the hub. When the flanges are aligned on the ends of the fluted drum, the raised hubs nest in the circular recesses on the ends of the drum and the raised spokes nest in the ends of the grooves to cooperatively form interlocking structure that interlocks the flanges with the drum and prevents the drum from rotating relative to the flanges.

The tie rods are inserted through the connection holes in the flanges and the grooves in the drum to removeably connect the flanges to the drum. The ends of the tire rods may have external threads for receiving internally threaded nuts or other fasteners for tightening and locking the flanges against the drum.

The cable reel assembly may be assembled by aligning the inner faces of the two flanges against opposite ends of the drum such that the raised hubs and raised spokes on the flanges nest in the circular recesses and grooves of the drum as described above. The tie rods are then inserted through the connection holes in one of the flanges and pushed through the vertices of the grooves in the drum until they extend from the connection holes in the opposite flange. Nuts or other fasteners are then threaded on the ends of the tie rods and tightened to lock the flanges on the drum.

To accommodate multiple types and sizes of cable, the components of the cable reel assembly may be formed in several different sizes and then selectively assembled to form cable reel assemblies of desired sizes. For example, two or more drums with different diameters and/or lengths and two or more flanges with different diameters may be formed and selectively attached together.

The cable reel assembly of the present invention provides several important advantages. For example, because the drums and flanges are rotationally molded of synthetic resin material, the cable reel assembly is relatively light weight and easy to transport and handle. The cable reel assembly also won't crack or warp and can therefore, be used multiple times and then eventually recycled at the end of its useful lives to save landfill space. Moreover, the modular design of the cable reel assembly allows its components to be manufactured and stored unassembled until needed, thus saving storage space. The modular design also allows users to create cable reel assemblies of several different sizes to accommodate different types and sizes of cable. After a cable reel assembly is used, it may be disassembled, stored, and then re-assembled when needed again.

This summary is provided to introduce a selection of concepts in a simplified form that are further described in the detailed description below. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other aspects and advantages of the present invention will be apparent from the following detailed description of the embodiments and the accompanying drawing figures.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

Embodiments of the present invention are described in detail below with reference to the attached drawing figures, wherein:

FIG. 1 is a perspective view of a cable reel assembly constructed in accordance with an embodiment of the present invention.

FIG. 2 is an exploded view of the cable reel assembly of FIG. 1.

FIG. 3 is a front or outside elevation view of one of the flanges of the cable reel assembly.

FIG. 4 is a rear or inside elevational view of one of the flanges.

FIG. 5 is a perspective view of the drum of the cable reel assembly.

FIG. 6 is and end view of the drum.

FIG. 7 is a vertical cross sectional view of the cable reel assembly.

The drawing figures do not limit the present invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention.

DETAILED DESCRIPTION

The following detailed description of embodiments of the invention references the accompanying drawings. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the claims. The following detailed description is, therefore, not to be taken in a limiting sense. The scope of the present invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.

In this description, references to “one embodiment”, “an embodiment”, or “embodiments” mean that the feature or features being referred to are included in at least one embodiment of the technology. Separate references to “one embodiment”, “an embodiment”, or “embodiments” in this description do not necessarily refer to the same embodiment and are also not mutually exclusive unless so stated and/or except as will be readily apparent to those skilled in the art from the description. For example, a feature, structure, act, etc. described in one embodiment may also be included in other embodiments, but is not necessarily included. Thus, the present technology can include a variety of combinations and/or integrations of the embodiments described herein.

Turning now to the drawing figures, and initially FIGS. 1 and 2, a cable reel assembly 10 constructed in accordance with embodiments of the invention is illustrated. The cable reel assembly 10 is provided for winding, unwinding, and storing cable, conduit, tubing, rope, chain, or any other elongated flexible or semi-flexible objects and broadly includes a fluted drum 12; a pair of circular flanges 14, 16 on opposite ends of the drum 12; and a number of elongated rods 18 that removably connect the flanges to the drum.

In more detail, an embodiment of the fluted drum 12 is best illustrated in FIGS. 5 and 6 and includes a hollow cylindrical core 20 and a number of circumferentially-spaced ribs 22 extending radially outwardly from the core 20. Embodiments of the ribs are wedge-shaped. The ribs 22 are separated by a number of grooves 24 spaced across the circumference of the drum. Each groove 24 is generally V-shaped due to the web shape of the adjacent ribs and has a rounded or curved vertex 26.

The drum 12 may include any number of ribs 22 and grooves 24. In one embodiment, the drum includes between six and twenty ribs and between six and twenty grooves. In one particular embodiment, the drum includes twelve ribs and twelve grooves.

As best illustrated in FIG. 5, the ends of the ribs 22 extend beyond the ends of the core 20 to define a circular recess 28 on each end of the drum. The purpose of the recesses 28 is described below.

The drum 12 may be formed in nearly any size to accommodate nearly any application. In one embodiment, the drum is between 12 and 90 inches in diameter (measured to the tips of the ribs 22) and between 12 and 90 inches long. As described below, several different sizes of the drum may be formed to permit the assembly of custom-sized cable reels.

The drum may be made of any suitable materials but is preferably rotationally molded of recyclable and reusable synthetic resin materials. The drum may be partially hollow to minimize its weight.

As best illustrated in FIGS. 2-4, the flanges 14, 16 are preferably circular in shape and each includes an inner face 30, 32, an outer face 34, 36 and a circumscribing radial wall 38, 40 connecting the faces. A number of spaced connection holes 42, 44 extend through the flanges and are aligned with the vertices 26 of at least some of the grooves 24 in the drum 12 for receiving the tie rods 18 as described below. A number of spaced key-hole shaped slots 46, 48 may be formed in the flanges by walls connecting the inner faces 30, 32 and outer faces 34, 36 of the flanges. The walls of these slots add rigidity and strength to the flanges. The flanges may also include a pair of arcuate slots 50, 52 between the faces of the flange and a pair of holes 53, 55 proximate the slots for use in tying off the ends of cable and other objects to be wound on the cable reel assembly.

Each of the flanges 14, 16 may also include a central arbor hole 54, 56 for accommodating a cable reel handling tool such as the Reel Thing manufactured by Tulsa Power, Inc. The tool may be inserted in either of the arbor holes for use in lifting, hanging, transporting, or otherwise moving the cable reel assembly 10. The arbor holes may be reinforced with metal inserts.

The inner face of each flange 14, 16 also includes a circular raised hub 58 and a number of circumferentially-spaced wedge-shaped recesses 60 that define a number of spaced raised spokes 62 that extend radially outwardly from the hub. Although present on both flanges, these features are only shown on the flange 14 in FIGS. 2 and 4. When the flanges 14, 16 are aligned on and attached to the ends of the fluted drum 12, the raised hubs nest in the circular recesses on the ends of the drum and the raised spokes nest in the ends of the grooves to cooperatively form interlocking structure that interlocks the flanges with the drum and prevents the drum from rotating relative to the flanges.

The flanges 14, 16 may be formed in nearly any size to accommodate nearly any application. In one embodiment, the flanges are between 24 and 160 inches in diameter and 1.5 and 6 inches thick. As described below, several different sizes of the flanges may be formed to permit assembly of custom-sized cable reels. As with the drum, the flanges may be made of any suitable materials but are preferably rotationally molded of recyclable and reusable synthetic resin materials and are partially hollow to minimize their weight.

The tie rods 18 are positioned in at least some of the grooves 24 of the fluted drum and extend through at least some of the connection holes 40, 42 in the flanges to removeably connect the flanges 14, 16 to the drum 12. The ends of the tire rods may have external threads for receiving internally threaded nuts or other fasteners for tightening and locking the flanges against the drum. Embodiments of the tie rods 18 are made of galvanized steel or other suitable materials and are between 12.5 and 90.5 inches long and 1/32 and ½ inches in diameter.

The cable reel assembly 10 may be assembled by aligning the inner faces of the two flanges against opposite ends of the drum such that the raised hubs and raised spokes on the flanges nest in the circular recesses and grooves of the drum. The tie rods are then inserted through the holes in one of the flanges and pushed through the vertices of the grooves until they extend from the holes in the opposite flange. Nuts or other fasteners are then threaded on the ends of the tie rods and tightened to lock the flanges on the drum.

To accommodate different types and sizes of cable, the components of the cable reel assembly may be formed in several different sizes and then selectively assembled to form a cable reel assembly of a desired size. For example, drums may be formed with 21″ and 28″ diameters and 28″ and 34″ lengths. Similarly, the flanges may be formed with 48″, 54″, and 60″ diameters. A user may then select the desired size drum and flanges and assemble them as described above to create a desired size cable reel assembly.

The cable reel assembly of the present invention has a number of advantages. For example, because the drums and flanges are rotationally molded of synthetic resin material, the cable reel assembly may be used over and over and eventually recycled at the end of its useful lives to save landfill space. Moreover, the modular design of the cable reel assembly allows its components to be manufactured and stored unassembled until needed, thus saving storage space. The modular design also allows users to create cable reel assemblies of several different sizes to accommodate different types and sizes of cable. Similarly, the load rating of the reel can be modified for any application by using more or less material in the rotational molding process. After use, the cable reel assembly may be disassembled for easier storage and then re-assembled when needed again.

Although the invention has been described with reference to the embodiments illustrated in the attached drawing figures, it is noted that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims. For example, the particular sizes and shapes of the components of the cable reel assembly may be changed and the hardware for connecting the components may be changed without departing from the scope of the invention. 

Having thus described the preferred embodiment of the invention, what is claimed as new and desired to be protected by Letters Patent includes the following:
 1. A reel assembly comprising: a fluted drum for winding an elongated object thereon, the fluted drum having a plurality of circumferentially-spaced ribs that define a plurality of circumferentially-spaced grooves between the ribs; a pair of circular flanges removably attached to opposite ends of the fluted drum, each flange having a number of spaced connection holes aligned with at least some of the grooves in the fluted drum; and a plurality of elongated rods positioned in at least some of the grooves of the fluted drum and extending through at least some of the connection holes in the flanges for removeably connecting the flanges to the fluted drum.
 2. The reel assembly as set forth in claim 1, the fluted drum having between six and twenty ribs and between six and twenty grooves between the ribs.
 3. The reel assembly as set forth in claim 2, the fluted drum having twelve ribs and twelve grooves between the ribs.
 4. The reel assembly as set forth in claim 1, each of the grooves having a generally V-shape with a rounded vertex.
 5. The reel assembly as set forth in claim 1, further comprising interlocking structure for interlocking the flanges and the drum to prevent the drum from rotating relative to the flanges.
 6. The reel assembly as set forth in claim 5, the interlocking structure comprising circular recesses on opposite ends of the drum, circular raised hubs on inner faces of the flanges that nest within the circular recesses, and a plurality of circumferentially-spaced raised spokes that extend from each of the hubs and nest within ends of the grooves in the drum.
 7. The reel assembly as set forth in claim 1, the flanges each having a central arbor hole for accommodating a cable reel handling tool.
 8. The reel assembly as set forth in claim 1, wherein the fluted drum and circular flanges are rotationally-molded of synthetic resin materials and are partially hollow.
 9. A reel assembly comprising: a fluted drum for winding an elongated object thereon, wherein the fluted drum is rotationally-molded of synthetic resin materials and is partially hollow, the fluted drum having a plurality of circumferentially-spaced ribs that define a plurality of circumferentially-spaced grooves between the ribs; a pair of circular flanges removably attached to opposite ends of the fluted drum, wherein each of the flanges is rotationally-molded of synthetic resin materials and has a number of spaced connection holes aligned with some of the grooves in the fluted drum; a plurality of elongated rods positioned in at least some of the grooves of the fluted drum and extending through at least some of the connection holes in the flanges for removeably connecting the flanges to the fluted drum; and interlocking structure for interlocking the flanges with the drum to prevent the drum from rotating relative to the flanges.
 10. The reel assembly as set forth in claim 9, the interlocking structure comprising circular recesses on opposite ends of the drum, circular raised hubs on inner faces of the flanges that nest within the circular recesses, and a plurality of circumferentially-spaced raised spokes that extend from each of the hubs and nest within ends of the grooves in the drum.
 11. The reel assembly as set forth in claim 9, the fluted drum having between six and twenty ribs and between six and twenty grooves between the ribs.
 12. The reel assembly as set forth in claim 11, the fluted drum having twelve ribs and twelve grooves between the ribs.
 13. The reel assembly as set forth in claim 9, each of the grooves having a generally V-shape with a rounded vertex.
 14. A modular and adjustable cable reel assembly comprising: a plurality of fluted drums each configured for winding a length of cable thereon, each fluted drum having a different diameter, wherein each fluted drum is rotationally-molded of synthetic resin materials and is partially hollow, each fluted drum having a plurality of circumferentially-spaced ribs that define a plurality of circumferentially-spaced grooves between the ribs; a pair of circular flanges that may be removably attached to opposite ends of either of the fluted drums so that the cable reel assembly may be assembled with a selected one of the drums of a desired diameter, wherein each of the flanges is rotationally-molded of synthetic resin materials and has a number of spaced holes axially aligned with at least some of the grooves in both the fluted drums; a plurality of elongated rods positioned in at least some of the grooves of the selected fluted drum and extending through at least some of the holes in the flanges for removeably connecting the flanges to the selected fluted drum; and interlocking structure for interlocking the flanges on the drum selected to prevent the selected drum from rotating relative to the flanges.
 15. The cable reel assembly as set forth in claim 14, the interlocking structure comprising circular recesses on opposite ends of the drums, circular raised hubs on inner faces of the flanges that nest within the circular recesses, and a plurality of circumferentially-spaced raised spokes that extend from each of the hubs and nest within ends of the grooves in the drums.
 16. The cable reel assembly as set forth in claim 14, each fluted drum having between six and twenty ribs and between six and twenty grooves between the ribs.
 17. The cable reel assembly as set forth in claim 14, each fluted drum having twelve ribs and twelve grooves between the ribs.
 18. The cable reel assembly as set forth in claim 14, each of the grooves having a generally V-shape with a rounded vertex. 